US9387370B2 - Co-forged golf club head and method of manufacture - Google Patents
Co-forged golf club head and method of manufacture Download PDFInfo
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- US9387370B2 US9387370B2 US14/078,380 US201314078380A US9387370B2 US 9387370 B2 US9387370 B2 US 9387370B2 US 201314078380 A US201314078380 A US 201314078380A US 9387370 B2 US9387370 B2 US 9387370B2
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Images
Classifications
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B60/00—Details or accessories of golf clubs, bats, rackets or the like
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B53/047—Heads iron-type
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21K—MAKING FORGED OR PRESSED METAL PRODUCTS, e.g. HORSE-SHOES, RIVETS, BOLTS OR WHEELS
- B21K17/00—Making sport articles, e.g. skates
-
- A63B2053/0416—
-
- A63B2053/042—
-
- A63B2053/0433—
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B2053/0491—Heads with added weights, e.g. changeable, replaceable
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B2209/00—Characteristics of used materials
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B53/0416—Heads having an impact surface provided by a face insert
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B53/0416—Heads having an impact surface provided by a face insert
- A63B53/042—Heads having an impact surface provided by a face insert the face insert consisting of a material different from that of the head
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B53/00—Golf clubs
- A63B53/04—Heads
- A63B53/0433—Heads with special sole configurations
-
- A—HUMAN NECESSITIES
- A63—SPORTS; GAMES; AMUSEMENTS
- A63B—APPARATUS FOR PHYSICAL TRAINING, GYMNASTICS, SWIMMING, CLIMBING, OR FENCING; BALL GAMES; TRAINING EQUIPMENT
- A63B60/00—Details or accessories of golf clubs, bats, rackets or the like
- A63B60/02—Ballast means for adjusting the centre of mass
Definitions
- the present invention relates generally to a co-forged golf club head formed from two or more materials and the method of manufacture for such a golf club head. More specifically, the present invention relates to the creation of an iron type golf club head from a pre-form billet that already contains two or more materials before the actual forging process; resulting in a multi-material golf club head that doesn't require any post manufacturing operations such as machining, welding, swaging, gluing, and the like.
- U.S. Pat. No. 4,523,759 to Igarashi discloses a perimeter weighted hollow golfing iron having a foam core with an effective hitting area concentrated toward the center of moment in an attempt to help make the game of golf easier. Distributing the weight of a golf club to the perimeter allow the moment of inertia (MOI) of a golf club head to be increased, reducing the undesirable twisting a golf club as it impacts a golf ball.
- MOI moment of inertia
- U.S. Pat. No. 4,809,977 to Doran et al. shows another example of an attempt to increase the moment of inertia of a golf club head by placing additional weights at the heel and toe portion of the golf club head.
- This increase in the moment of inertia of the golf club head achievable by increased heel and toe weighting could further prevent the golf club from twisting in a heel and toe direction, which mitigates the undesirable effect of sending a golf ball off the intended trajectory.
- U.S. Pat. No. 5,885,170 to Takeda shows the advantage of using multi-materials to create more extreme adjustment of the mass properties. More specifically, U.S. Pat. No. 5,885,170 teaches a body having a face formed of one material while a hosel is formed from another material having different specific gravity from that of the head body.
- U.S. Pat. No. 6,434,811 to Helmstetter et al. shows another example of utilization of multiple materials to improve the performance of a golf club head by providing a golf club head with a weighting system that is incorporated after the entirety of the golf club head has been formed.
- U.S. Pat. No. 7,938,739 to Cole et al. discloses a golf club head with a cavity integral with the golf club head, wherein the cavity extends from the heel region to the toe region; extending along a lower portion of the back face of the golf club head; extends approximately parallel to the strike face; and is approximately symmetrical about a centerline that bisects the golf club head between the heel region and the toe region.
- U.S. Pat. No. 6,095,931 to Hettinger et al. identifies this specific undesirable side effect of sacrifice in the feel by the usage of multiple different components.
- U.S. Pat. No. 6,095,931 addresses this issue by providing an isolation layer between the golf club head and the main body portion that comprises the striking front section.
- U.S. Pat. No. 7,828,674 to Kubota recognizes the severity of this problem by stating that hollow golf club heads having viscoelastic element feels light and hollow to the better golfer, hence they do not prefer such a golf club.
- U.S. Pat. No. 7,828,674 address the deficiencies of such a multi-material golf club by incorporating a block of magnesium to be embedded and or press-fitted into the recess formed in the metal only to be sealed with a metallic cover.
- a forged golf club head comprising a body portion having a striking surface made out of a first material, and at least one weight adjustment portion made out of a second material encased within the body portion; wherein the at least one weight adjustment portion is encased monolithically within the body portion of the golf club head without any secondary attachment operations.
- a method of forging a golf club head comprising of the steps of creating a cylindrical billet out of a first material, machining one or more cavities within the cylindrical billet, partially filling the one or more cavities with a second material to create a weight adjustment portion, filling the remaining volume of the one or more cavities with the first material to encase the weight adjustment portion, and forging the cylindrical billet to create a body portion of the golf club head; wherein the body portion monolithically encases the weight adjustment portion within a body of the golf club head without any secondary attachment operations.
- a forged golf club head comprising a body portion having a striking surface made out of first material, and at least one weight adjustment portion made out of a second material encased within the body portion; wherein the at least one weight adjustment portion is encased monolithically within the body portion without any secondary attachment operations.
- the first material has a first flow stress at a first forging temperature and the second material has a second flow stress at a second forging temperature, wherein the first flow stress and the second flow stress are substantially similar to one another, and the first forging temperature and the second forging temperature are substantially similar to one another and the first forging temperature and the second forging temperature are substantially similar to one another.
- the first material has a first thermal expansion coefficient and the second material has a second thermal expansion coefficient, wherein the first thermal expansion coefficient is greater than or equal to the second thermal expansion coefficient.
- FIG. 1 of the accompanying drawings shows a perspective view of a co-forged golf club head in accordance with an exemplary embodiment of the present invention
- FIGS. 2A-2D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention
- FIGS. 3A-3D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention
- FIGS. 4A-4D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention
- FIGS. 5A-5D shows perspective views of pre-formed billets used to create a golf club head in accordance with an exemplary embodiment of the present invention
- FIG. 6 shows an exploded rear perspective view of a golf club head created using a multi-step co-forging method in accordance with a further alternative embodiment of the present invention
- FIG. 7 shows an exploded frontal perspective view of a golf club head created using a multi-step co-forging method in accordance with a further alternative embodiment of the present invention
- FIG. 8 shows a pre-formed billet used in a multi-step co-forging method to create a golf club head in accordance with an alternative embodiment of the present invention
- FIG. 9 shows a bent pre-formed billet during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention.
- FIGS. 10 a and 10 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention
- FIGS. 11 a and 11 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention
- FIGS. 12 a and 12 b shows a rear and frontal exploded view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention
- FIGS. 13 a and 13 b shows a rear and frontal view of a golf club head during one of the multi-step co-forging process in accordance with an alternative embodiment of the present invention
- FIGS. 14 a and 14 b shows a rear and frontal view of a finished golf club head after the multi-step co-forging in accordance with an alternative embodiment of the present invention.
- FIG. 15 shows a frontal view of a golf club head in accordance with an alternative embodiment of the present invention.
- FIG. 16 shows a frontal view of a golf club head in accordance with an alternative embodiment of the present invention without the striking face showing a cavity;
- FIG. 17 shows a perspective exploded view of a golf club head in accordance with an alternative embodiment of the present invention.
- FIG. 18 show a back view of a golf club head in accordance with an alternative embodiment of the present invention.
- FIG. 19 shows a toe side exploded view of a golf club head in accordance with an alternative embodiment of the present invention.
- FIG. 20 shows a heel side exploded view of a golf club head in accordance with an alternative embodiment of the present invention.
- FIG. 1 of the accompanying drawings shows a perspective view of a golf club head 100 in accordance with an exemplary embodiment of the present invention.
- the golf club head 100 shown in FIG. 1 may generally comprise of a body portion 102 and a hosel portion 104 , with the body portion 102 having several individually identifiable components such as a topline portion 106 , a sole portion 108 , a heel portion 110 , and a toe portion 112 .
- the golf club head 100 in accordance with an exemplary embodiment of the present invention may generally be comprised of at least one weight adjustment portion that is encased within the body portion 102 of the golf club head 100 .
- the weight adjustment portion may be monolithically encased within the body portion 102 to ensure that the weight adjustment portion is secured within the body portion 102 without departing form the scope and content of the present invention. Because the weight adjustment portion is monolithically encased within the body portion 102 of the golf club head 100 , these weights are not visible in FIG. 1 of the accompanying drawings. However, these weight adjustment portions will be shown in more detail in later figures, when various different views are presented.
- “Monolithically encased”, as referred to in the current patent application, may generally be defined as a having a specific internal component placed inside a separate external component without joints or seams in the finished product.
- having weight adjustment portions “monolithically encased” within the body portion 102 of the golf club head 100 may generally refer to the ability to have weight adjustment portions placed inside the body portion 102 of the golf club head without joints or seams that are generally required by post manufacturing processes such as milling, welding, brazing, gluing, or swaging.
- a weight that is “monolithically encased” within the current definition of the present invention could potentially have certain aspect of the internal weights exposed in the finish product to illustrate the existence of a weight adjustment portion without departing from the scope and content of the present invention. More specifically, “monolithically encased” refers to the methodology used to create the ultimate product as described above, and may not necessarily be limited to visually concealing the weight adjustment member.
- FIGS. 2A-2D illustrate the methodology used to create a co-forged golf club head 200 in accordance with an exemplary embodiment of the current invention. More specifically, FIGS. 2A-2D illustrate the steps involved in the forging of a golf club head from its rudimentary billet 201 shape into the final product of a golf club head 200 .
- FIG. 2A shows a pre-formed billet 201 in accordance with an exemplary embodiment of the present invention.
- the pre-form billet 201 may generally begin as a cylindrical rod formed from a first material, as it is common with the forging of a golf club head 200 .
- one or more cavities 216 are machined into the pre-form billet 201 .
- two cavities 216 are machined into the terminal ends of the pre-form billet 201 .
- the location and geometry of the cavities 216 within the pre-form billet 201 are important, as it correlates directly with the ultimate location of the weight adjustment portion 215 in the golf club head 200 after forging.
- the cavities 216 are partially filled with a second material that has a density different from the density of the first material in order to create the weight adjustment portion. 215 .
- the location, size, and shape of the weight adjustment portion 215 is just as critical as the location, size, and shape of the cavities 216 , as the weight adjustment portion 215 within the pre-form billet 201 correlates with the ultimate resting place of the weight adjustment portion 215 in the golf club head.
- FIG. 2C shows the final phase of the pre-form billet 201 as the remaining volume of the cavities 216 are filled with the first material and sealed through traditional joining methods such as welding, brazing, and swaging. Sealing the cavities 216 allows the weight adjustment portion 215 to be monolithically encased within the body of the pre-form billet 201 , which will allow the same weight adjustment portion 215 to be monolithically encased in the body 202 of the golf club head 200 after the forging process. After the cavities 216 are filled, the pre-form billet 201 is subjected to the normal forging process associated with the forging of a golf club head 200 .
- the above discussion regarding the forging of a golf clubs incorporated by reference do a good job describing the actual forging process, it fails to address the additional concerns with the co-forging process of the current invention wherein two different materials are involved in this forging process. More specifically, because a weight adjustment portion 215 is made out of a second material that could be different from the first material used to create remainder of the pre-form billet 201 , special care must be taken to ensure that the different materials can be forged together to form a golf club head 200 . Hence, in order to select two cohesive materials that are capable of being co-forged together, the first material and the second material may generally have to have very specific material properties requirements with respect to their flow stress and their thermal expansion coefficient. Although it is most preferential for the two materials to have identical material properties yielding in consistency in forging, the usage of identical materials may not offer any weight adjustment benefits required for the basis of the current invention.
- a first flow stress of the first material at its first forging temperate is substantially similar but not identical to the second flow stress of the second material at its second forging temperature; with the first forging temperature and the second forging temperature being substantially similar.
- the first material may be 1025 steel having a first flow stress of about 10 ksi (kilo-pound per square inch) at a forging temperature of about 1,200° C.
- the second material may a Niobium material having a second flow stress of also about 12 ksi at a forging temperature of about 1,100° C.
- the first material may be a 1025 steel and the second material may be a Niobium material
- various other materials may also be used without departing from the scope and content of the present invention so long as their flow stresses are similar at a similar forging temperature.
- any two materials may be used in the current co-forging process so long as the second flow stress is no more than 20% greater or no less than 20% lesser than the first flow stress.
- the thermal expansion coefficient of the first and second materials are also important to the proper co-forging of two distinct materials. More specifically, a first thermal expansion coefficient of the first material may generally need to be greater than or at least equal to the second thermal expansion coefficient of the second material. Because the thermal expansion coefficient also relate to the shrinkage of the material after forging, it is important that the first material that monolithically encases the second material have a higher thermal expansion coefficient to prevent gaps from forming at the interface portion of the materials.
- the first material may be 1025 steel having a thermal expansion coefficient of about 8.0 ⁇ in/in ° F.
- the second material may be Niobium having a second thermal expansion coefficient of about 3.94 ⁇ in/in ° F.
- the second thermal expansion coefficient is smaller than the first thermal expansion coefficient
- the numbers can be identical to achieve perfect mating of the two materials without departing from the scope and content of the present invention.
- the second material could be made out of a 6-4 Titanium material to reduce the weight of the weight adjustment portion 215 .
- the Titanium material may generally have a flow stress of about 10 ksi at a forging temperature of about 1,100° C. and a thermal expansion coefficient of about 6.1 ⁇ in/in ° F.
- FIG. 2D of the accompanying drawings shows a perspective view of a finished golf club head 200 created using the co-forging process above, wherein the golf club head 200 monolithically encases at least one weight adjustment portion 215 within the body portion 202 . More specifically, in the current exemplary embodiment of the present invention, the weight adjustment portions 215 are placed near a heel portion 210 and a toe portion 212 of the golf club head 200 .
- the placement of the weight adjustment portion 215 near a heel portion 210 and the toe portion 212 allow the golf club head 200 to have an increase in the Moment of Inertia (MOI) without the need for any secondary attachment operations; which will result in a more consistent feel upon impact with a golf ball.
- MOI Moment of Inertia
- the exact placement of the weight adjustment portion 215 within the body portion 202 of the golf club head 200 is slightly different in every single different club head, this is the outcome of the current inventive co-forging process involves different materials. More specifically, the exact placement of the weight adjustment portion 215 may differ with each single golf club 200 , as the flow stress of the first material and the second material will help determine the final location of the weight adjustment portion 215 .
- the interface between the weight adjustment portion 215 and the body portion 202 of the golf club head 200 may generally be an irregular interface, with the boundaries jagged to indicate that the entire golf club head 200 has been co-forged. This is dramatically different from a cavity created via a post machining secondary operations such as milling and drilling; which generally have clean bifurcation lines of the two different materials.
- FIGS. 3A-3D of the accompanying drawings shows an alternative embodiment of the present invention wherein two separate weight adjustment portions 314 and 315 are placed at different portions of the pre-form billet 301 to create a golf club head 300 with a different performance criteria. More specifically, the golf club head 300 shown in FIG. 3D may have a lightweight weight adjustment portion 314 near a topline portion 306 of the golf club head 300 and a heavyweight weight adjustment portion 315 near a sole 308 of the golf club head 300 to help shift the Center of Gravity (CG) of the golf club head 300 lower to help with launch and spin characteristics of the current inventive golf club head 300 .
- CG Center of Gravity
- FIG. 3A-3C similar to before, show the formation process of the current inventive golf club head 300 , starting from a pre-form billet 301 . More specifically, FIG. 3A shows a perspective view of a pre-form billet 301 in accordance with an exemplary embodiment of the present invention wherein a plurality of cavities 316 are drilled at strategic locations within the billet 301 .
- the plurality of cavities 316 are drilled near a top portion and a bottom portion of the pre-form billet 301 instead of at each of the terminal ends, as this specific embodiment focuses on lowering the CG of the golf club head 300 by removing weight from the top line portion 306 of the golf club head 300 and shifting it towards a sole portion 308 of the golf club head 300 .
- FIG. 3B of the accompanying drawings shows two weight adjustment portions 314 and 315 being placed inside the cavities 316 created in FIG. 3A .
- top cavity 316 can not be left completely blank in this current embodiment of the present invention, as the entire pre-form billet 301 will eventually be forged into the shape of a golf club head 300 , causing any empty cavity 316 to collapse upon itself.
- the top cavity 316 may be filled with a lightweight weight adjustment portion 314
- the lower cavity 316 may be filled with a heavyweight weight adjustment portion 315 .
- the lightweight weight adjustment portion 314 may generally be made out of a third material having a third density, wherein the heavyweight weight adjustment portion 315 may generally be made out of second material having a second density.
- the third density may generally be less than about 7.0 g/cc, wherein the second density may generally be greater than about 7.8 g/cc; while the first material used to form the body portion 302 of the golf club head 300 may generally have a first density of about 7.8 g/cc.
- FIG. 3C of the accompanying drawings shows the final stage of the pre-form billet 301 that has monolithically encased the weight adjustment portions 314 and 315 within the internal cavities 316 of the pre-form billet 301 .
- the creation of the pre-form billet shown in FIG. 3C involves filling in the remaining volume of the cavities 316 with a first material to encase the weight adjustment portions 315 and 316 within the pre-form billet 301 .
- the pre-form billet 301 is subsequently forged to create a golf club head 300 as shown in FIG. 3D , wherein the weight adjustment portions 314 and 315 are monolithically encased within the body portion 302 of the golf club head 300 .
- the third material may generally need to have a third flow stress that is similar with the first flow stress of the first material and a third thermal expansion coefficient less than the first thermal expansion coefficient of the first material. More specifically, in one exemplary embodiment of the present invention, the third material may be a 6-4 Titanium material having a third flow stress of about 10 ksi at a forging temperature of about 1,100° C. and a third thermal expansion coefficient of about 6.1 ⁇ in/in ° F.
- FIGS. 2A-2D and FIGS. 3A-3D show different embodiments of the present invention used to achieve a higher MOI and a lower CG respectively, these features are not mutually exclusive from one another.
- FIGS. 4A-4D features may be taken from both embodiments discussed above to create a co-forged golf club head with a higher MOI as well as a lower CG all without departing from the scope and content of the present invention. More specifically, in FIGS.
- FIG. 5A-5D of the accompanying drawings shows a further alternative embodiment of the present invention wherein the body portion 502 of the golf club head 500 may be comprised of a monolithically encased weight adjustment portion 514 .
- the weight adjustment portion 514 may be relatively large in size, allowing it to replace a majority of the body portion 502 of the golf club head 500 once the forging process is completely.
- the monolithically encased weight adjustment portion 514 may generally be made out of a third material having a third density that is significantly lower than the first density of the first material used to form the body portion 502 of the golf club head 500 ; allowing weight to be taken out from the body portion 502 of the golf club head 500 . Because the lightweight third material used to form the weight adjustment portion 514 may generally be relatively soft compare to the first material, it is generally desirable to monolithically encase the weight adjustment portion 514 within the internal body of the golf club head 500 , allowing significant weight savings to be achieved without sacrificing feel.
- FIG. 5A of the accompanying drawings shows a pre-form billet 501 similar to the previous figures.
- the cavity 506 is significantly larger within the pre-form billet 501 itself.
- This large cavity 506 can then be used in FIG. 5B to be filled with a weight adjustment portion 514 to adjust the weight, density, and overall feel of the golf club head 500 .
- FIG. 5C similar to described above, the remaining volume of the cavity 516 is filled with the original first material before the entire pre-form billet 501 is subjected to the forging process to create a golf club head 500 .
- the hosel portion 504 of the golf club head 500 is deliberately made from the conventional first material, as the bending characteristics of the second material used to form the weight adjustment portion 514 may generally not be suitable for the bending requirements of an iron type golf club head 500 .
- the third material used to form the weight adjustment portion 514 could be a lightweight iron-aluminum material having a density of less than about 7.10 g/cc, more preferably less than about 7.05 g/cc, and most preferably less than about 7.00 g/cc, all without departing from the scope and content of the present invention.
- numerous other materials can also be used as the third material used to form the weight adjustment portion 514 without departing from the scope and content of the present invention so long as the third material has a density within the range described above.
- FIG. 6 of the accompanying drawings shows an exploded rear perspective view of a golf club head 600 in accordance with a further alternative embodiment of the present invention utilizing a multi-step co-forging process.
- This multi-step co-forging process allows for an improvement in the ability to precisely place different weight members within different parts of the golf club head 600 .
- This improvement in the ability to precisely place weighting members not only opens the door to allow multiple different materials to be forged together that were previously impossible due to their inherent material limitations, but it also allows for more improvements in the performance characteristics of a golf club 600 than previously discussed.
- FIG. 6 of the accompanying drawings shows a co-forged golf club head 600 created using the multi-step co-forging process.
- the golf club head 600 have heavier density weight adjustment portions 615 at the heel 610 and toe 612 portion of the golf club head 600 corresponding to their respective cavities 616 .
- the weight adjustment portions 615 are then combined with caps 617 to retain the weight adjustment portions 615 together with the body of the golf club head 600 during the co-forging process.
- the current exemplary golf club head 600 utilizes a multi-step co-forging process to install the heavy weight adjustment portions 615 without the need of post manufacturing finishes such as welding, brazing, swaged, or the like.
- the benefit of utilizing such a co-forged process is the uniformity and consistency of the material, resulting in superior performance and feel.
- the current embodiment of the present invention allows the heavy weight adjustment portions 615 to be placed at the extremities of the golf club head 600 , further improving the center of gravity location as well as the moment of inertia of the golf club head 600 .
- FIG. 7 of the accompanying drawings shows an exploded frontal perspective view of a golf club head 700 in accordance with a further alternative embodiment of the present invention. More specifically, golf club head 700 incorporates a lightweight weight adjustment portion 714 behind a striking face 718 portion of the golf club head 700 within a cavity 716 in a multi-step co-forging process.
- the location and placement of the lightweight weight adjustment portion 714 can be more precisely placed, hence creating the opportunity to reduce weight from the striking face 718 portion of the golf club head 700 .
- FIGS. 8-14 have been presented below, detailing the steps involved in this multi-step co-forging process.
- FIG. 8 of the accompanying drawings similar to FIGS. 2-5 above, show a pre-form billet 801 used to create a forged golf club head.
- This forged billet 801 is then bent to an L-shape as shown in FIG. 9 to prepare the billet 901 for the die that begins the forging process.
- FIGS. 10 a and 10 b shows the frontal and rear view of a golf club head 1000 that's been subjected to the first step of the multi-step co-forging process. In this preliminary step, the billet has been forged to a shape that roughly resembles that of a golf club head 1000 .
- the shape of the golf club 1000 can be seen, as it already has a hosel portion 1004 , a heel portion 1010 , and a toe portion 1012 .
- preliminary imprints of the cavity 1016 can already be seen in the heel 1010 and toe 1012 portion of the golf club head; while in the frontal view of the golf club head 1000 shown in FIG. 10 b , the cavity 1016 can already be seen near the striking face.
- the excess trim 1030 may be removed from the golf club head 1000 and subsequent to that, subjected to another rough forging step.
- the excess material may flow outside of the confines of the die, resulting in what is commonly known as “flash”. This flash material, as previously discussed, may be trimmed off in between the individual multi-forging steps to improve the adherence to the die in subsequent steps.
- FIGS. 11 a and 11 b The results of this secondary forging step can be shown in FIGS. 11 a and 11 b .
- the golf club head 1100 in this current state is starting to take on a shape that more closely resembles that of a finished product.
- the boundaries and shapes of the cavities 1116 are also starting to take on their respective shape as well.
- the weight adjustment portions can be added into the specific cavities 1116 before the golf club head 1100 is subjected to the final forging step.
- FIGS. 12 a and 12 b The relationship between the weight adjustment portions to the cavities 1116 on the golf club head 1100 can be shown more clearly in FIGS. 12 a and 12 b .
- the cavity 1216 on the rear portion of the golf club head 1200 may be filled with weight adjustment portions 1215 that may generally have a higher density than the body of the golf club head 1200 .
- the high density weight adjustment portions 1215 may then be covered up with a cap 1217 made out of a similar material as the body of the golf club head 1200 , allowing high density weight adjustment portions 1215 to be retained within the cavity 1216 .
- the cavity 1216 may be filled with a weight adjustment member 1214 having a lower density than the body portion of the golf club head 1200 . Similar to the rear, this weight adjustment portion 1214 may be secured in the cavity 1216 with a cap like mechanism that also serves as a striking face 1218 .
- the striking face 1218 similar to the cap 1217 , may be made out of a similar material as the body of the golf club head 1200 . Having the cap 1217 and the striking face 1218 be made out of the same material as the remainder of the body of the golf club head 1200 is beneficial because it allows these two components to be welded to the body portion of the golf club head 1200 . Having these components welded in place allows the weight adjustment portions 1215 to be secured within their own respective cavities 1216 before the final forging step that completes the current multi-step co-forging process.
- the cap 1217 may not even be necessarily needed to completely cover up the cavity 1216 and the weight adjustment member 1214 . In fact, in an alternative embodiment of the present invention, the cap 1217 only needs to partially cover the weight adjustment portion 1215 to a degree that sufficiently prevents the weight adjustment portion 1215 from separating from the body of the golf club head 1200 .
- the final forging process involved in this process is generally creates a golf club head 1200 that can be considered “co-forged”, as now the golf club head 1200 contains two or more different materials being forged together in this final step.
- FIGS. 13 a and 13 b show the results of the golf club head 1300 after it has completed the final co-forging step.
- the golf club head 1300 In its current state, the golf club head 1300 has taken its final shape, and the weight adjustment members 1316 and 1314 are all now monolithically enclosed within their respective cavities by the caps 1317 and striking face plate 1318 .
- the golf club head 1300 may have taken their form, there are still excessive flash 1330 around the perimeter of the golf club head 1300 that needs to be trimmed before the golf club head 1300 takes its final form.
- FIGS. 14 a and 14 b show the completed golf club head 1400 as a result of this co-forging process.
- the excess flash 1330 has already been trimmed, improving the aesthetic appeal of the golf club head 1400 .
- the weight adjustment portions 1416 and 1418 are seamlessly and monolithically encased with the body of the golf club head 1400 via the cap 1417 and the striking face plate 1318 .
- the advantage of having the weight adjustment portions 1416 seamlessly and monolithically encased with the body of the golf club head 1400 via this co-forged process is that it prevents rattling, and improves the solid feel of the golf club head 1400 .
- the present golf club head can achieve a feel that is almost non-discernible from a unitary forged golf club head utilizing conventional forging methodologies.
- this present multi-step co-forging methodology creates a unique relationship between the weight adjustment portions 1416 and 1418 and the cavity 1216 (see FIG. 12 ) that it sits in. More specifically, it can be said that the outer surface area of the weight adjustment portion 1416 may generally be identical to the inner surface area of the cavity 1216 .
- the cavity 1216 may generally include the surface area of any caps 1217 or face plate 1218 used to complete the cavity 1216 created by the rough forging steps. (See FIG.
- FIG. 15 of the accompanying drawings shows a frontal view of a finished product golf club head 1500 in accordance with an alternative embodiment of the present invention utilizing the co-forged technology previously described.
- the striking face insert 1518 may only partially cover the lower portion of the golf club head 1500 , allowing a cavity to be created only in the lower portion of the golf club head 1500 .
- This specific bifurcation of the club head 1500 may be beneficial in improving the performance of the golf club head 1500 in creating a dual cavity design that provides structural support near the central hemisphere of the club head 1500 to provide a more solid feel during impact.
- FIG. 16 of the accompanying drawings shows a frontal view of a golf club head 1600 without the striking face insert 1518 (shown in FIG. 15 ).
- This view of the golf club head 1600 allows the internal face cavity 1616 to be shown more clearly, illustrating a plurality of support rods 1630 that may be used to further provide structural support to the striking face portion.
- the plurality of rods 1630 may be circular rods as shown in FIG. 16 dispersed throughout the internal walls of the face cavity 1616 .
- the plurality of rods 1630 may not even be cylindrical, but be square, rectangular, or any other shape all without departing from the scope and content of the present invention so long as it is provides any sort of localized support for the striking face.
- the placement of the rods 1630 need not be dispersed throughout the internal walls of the face cavity 1616 , in fact, the location of the rods 1630 may be placed at any one of many numerous locations all without departing from the scope and content of the present invention.
- the face cavity 1616 may not even require any supporting rods 1630 , and the face cavity 1616 may be entirely hollow without departing from the scope and content of the present invention.
- FIG. 17 of the accompanying drawings shows an exploded perspective view of a golf club head in accordance with the embodiment of the present invention shown in FIGS. 15 and 16 . More specifically, this exploded view allows the relationship and fit between the striking face insert 1718 and the face cavity 1716 of the golf club head 1700 to be shown more clearly.
- the connection between the striking face insert 1718 and the body of the golf club head 1700 involves a hollow face cavity 1716 portion that could cause the striking face insert 1718 to deform during a forging process.
- the material used for the striking face insert 1718 may be similar to that of the body portion 1700 , allowing the two components to be joined together using a conventional welding process after the other components are co-forged together.
- the plurality of rods 1730 may generally touch the rear surface of the striking face insert 1718 .
- the terminal ends of the plurality of rods 1716 may contact a rear surface of the striking face insert 1718 to provide the structural enhancement.
- the terminal ends of the plurality of rods 1716 may terminate just short of the rear surface of the striking face insert 1718 creating a gap; promoting face flexure upon impact with a golf ball while creating a backstop to preserve the elastic deformation of the striking face insert 1718 material.
- FIG. 18 of the accompanying drawings shows a back view of a golf club head 1800 having one or more weights 1815 and caps 1817 joined together using the co-forged process described above. Without repeating the process described above, FIGS. 19-20 will show a toe and heel exploded view of the various components that will be created using the co-forged process described above.
- FIG. 19 shows an exploded toe perspective view of a golf club head 1900 illustrating the various components of the weighting system in accordance with this embodiment of the present invention.
- the exploded view of the golf club head 1900 is not illustrative of the methodology used to create the weighting system, but rather is only presented here to illustrate how the components could be used together in the co-forging process described above to create the golf club head 1900 .
- the weighting system here comprises a weight cavity 1916 , a weight 1915 , a cap 1979 , and welding material 1920 .
- the weight cavity 1916 is formed here in the rough forging step, after which the weight 1915 is tack welded within the weight cavity 1916 with the cap 1917 using the welding material 1920 .
- the entire golf club head 1900 is subjected to a final forging step as described above in FIGS. 13 a and 13 b.
- FIG. 20 shows an exploded heel perspective view of a golf club head 2000 illustrating the various components of the weighting system in accordance with this embodiment of the present invention. Similar to the discussion above for FIG. 19 , this view is provided to illustrate the relationship between the components.
- the current multi-step co-forging process may differ from the pure co-forging process in that it no longer requires the two materials to have similar flow stresses between the different materials. This elimination of the requirement that the material needs to have similar flow stresses may be beneficial because it allows a wider range of materials to be used, especially when it comes to exotic materials providing extreme weighting benefits such as Tungsten.
- the current multi-step co-forging process is capable of achieving this by forging the cavity for the weight before using a final cap type material to fill the gap around the cavity to completely enclose the weight adjustment portion within the cap type material.
- the need for the second material to have a smaller thermal expansion coefficient as the first material still stands true in this multi-step co-forging process. This requirement still stands because the second material, although encompassed in a cavity via a cap, is still subjected to the same forging temperature as the external first material. Any excessive expansion of the second material would degrade the structural rigidity of the cap, causing potential failures in the bonding process.
Abstract
Description
Y f =Ke n Eq. (1)
wherein
Claims (11)
Priority Applications (19)
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US14/078,380 US9387370B2 (en) | 2011-11-28 | 2013-11-12 | Co-forged golf club head and method of manufacture |
CN201420681700.7U CN204485237U (en) | 2013-11-12 | 2014-11-12 | Forging glof club head |
US14/580,894 US9616303B2 (en) | 2011-11-28 | 2014-12-23 | Co-forged golf club head and method of manufacture |
US15/065,104 US20160184669A1 (en) | 2011-11-28 | 2016-03-09 | Co-forged golf club head and method of manufacture |
US15/182,275 US20160287955A1 (en) | 2011-11-28 | 2016-06-14 | Golf club head and method of manufacture |
US15/188,726 US10398951B2 (en) | 2011-11-28 | 2016-06-21 | Co-forged golf club head and method of manufacture |
US15/332,864 US10391370B2 (en) | 2011-11-28 | 2016-10-24 | Co-forged golf club head and method of manufacture |
US15/455,781 US10071292B2 (en) | 2011-11-28 | 2017-03-10 | Co-forged golf club head and method of manufacture |
US15/713,374 US20180036605A1 (en) | 2011-11-28 | 2017-09-22 | Set of golf club heads and method of manufacture |
US16/000,021 US20180280768A1 (en) | 2011-11-28 | 2018-06-05 | Golf club head and method of manufacture |
US16/228,141 US20190118049A1 (en) | 2011-11-28 | 2018-12-20 | Co-forged golf club head and method of manufacture |
US16/406,382 US11065513B2 (en) | 2011-11-28 | 2019-05-08 | Set of golf club heads and method of manufacture |
US17/338,435 US20210291025A1 (en) | 2011-11-28 | 2021-06-03 | Co-forged golf club head and method of manufacture |
US17/351,702 US11504589B2 (en) | 2011-11-28 | 2021-06-18 | Set of golf club heads and method of manufacture |
US17/688,326 US11918867B2 (en) | 2011-11-28 | 2022-03-07 | Co-forged golf club head and method of manufacture |
US17/882,354 US20220370868A1 (en) | 2011-11-28 | 2022-08-05 | Co-forged golf club head and method of manufacture |
US17/981,883 US20230057513A1 (en) | 2011-11-28 | 2022-11-07 | Set of golf club heads and method of manufacture |
US18/483,220 US20240033590A1 (en) | 2011-11-28 | 2023-10-09 | Set of golf club heads and method of manufacture |
US18/487,711 US20240042289A1 (en) | 2011-11-28 | 2023-10-16 | Co-forged golf club head and method of manufacture |
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US13/305,087 US8926451B2 (en) | 2011-11-28 | 2011-11-28 | Co-forged golf club head and method of manufacture |
US13/927,764 US20130288823A1 (en) | 2011-11-28 | 2013-06-26 | Co-forged golf club head and method of manufacture |
US14/078,380 US9387370B2 (en) | 2011-11-28 | 2013-11-12 | Co-forged golf club head and method of manufacture |
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US15/065,104 Continuation-In-Part US20160184669A1 (en) | 2011-11-28 | 2016-03-09 | Co-forged golf club head and method of manufacture |
US15/182,275 Continuation-In-Part US20160287955A1 (en) | 2011-11-28 | 2016-06-14 | Golf club head and method of manufacture |
US15/188,726 Continuation-In-Part US10398951B2 (en) | 2011-11-28 | 2016-06-21 | Co-forged golf club head and method of manufacture |
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